Inlaid fibrous bodied articles, and method of producing same



Feb.2, 1937. E, SLAN 2,069,393

INLAID FIBROUS BODIED ARTICLES AND METHOD OF PRODUCING SAME Original Filed May 19, 1934 da la n l/ J J Patented Feb. 2, 1 937 UNITED STATES PATENT oFF-ICE INLAID FIBROUS BODIED ARTICLES, AND METHOD F PRODUCING SAME Edward C. Sloan, Geneva, Ill., assigner to Jesse B. Hawley, Geneva, Ill.

application May 19,

8 Claims. (Cl. 41-r-35) The present invention relates to the producing of articles the bodies of which are of fibrous material and are so provided with a thermoplastic substance'of a resinous base as to present in the produced articles given and predetermined physical properties and characteristics with or without decorative or artistic eiects, and among the objects of the invention is to provide novel articles of the character mentioned above and a novel process of producing the same. f

The method or process of this invention generally comprises providing the article body with a thermoplastic substance having the characteristics and properties later more fully described, with or without decorative or ornamentalvmeans or media, and subjecting the aggregate to heat and pressure to eiect the finished article.

qThe thermoplastic substance referred to is in the class of synthetic resinous compounds known as the vinyl resins of the polymerization group and more particularly those which are permanently thermoplastic, characterized by the bond group or radical -CH:CH2, and which are insoluble in most all known solvents, particularly the hydrocarbon solvents, except the solvents of thev ester type or the higher ketones, such as hexone and butyrone. In other words, the substance used in this invention is chemically inert to the extent indicated above and hence is impervious to and proof against moisture, waterJ acids', alkalies, alcohols, oils, greases, fats, and the like. In its normally pure state it is odorless, tasteless, colorless, and transparent. It is also noninflammable. It may be given any color or made translucent or opaque as desired by the incorporating or mixing therewith of dyes, pigments, fillers, or the like. It is also tough, durablev and resilient. It also hasa very strong bonding or adhesive property. If a pliant characteristic be desired, a plasticizer may be added to it to the extent of the pliability required. It may be applied either in liquid or'solid form or both. In the solid or non-liquid state it may be in any desired form, such as; sheets, illms, strips, bars, rods, and the like. When using this substance in liquid form, acetone preferably is usedv as the solvent but it is to be understood other solvents as mentioned above may be used without affecting theidea of invention herein disclosed.

Another object of the invention is'to provide a novel method'of producing inlays or the like and a novel article having suchv inlays and similar decorative features.

Other objects, capabilities, advantages, and the like, are comprehended by the invention as will later appear and as are inherently possessed by the invention.

This is a division of my co-pending application identied under Serial No. 726,610, led May Referring to the drawing:

Fig. 1 is a face view of part of an article wall showing decoration with inlays effected in a, novel manner;

Fig. 2 is a section taken in planes represented 10 by line 3-3 in Fig. 1 before'the elements are compressed;

' Fig. 3 is a similar view after the elements have been compressed;

Fig. 4 is a view similar to Fig. 2 but taken in l5 a transverse plane represented-by line 5- 5 in Fig. 1 of the drawing, showing the elements before compression; and,

Fig. 5 is a similar view showing the elements after compression.

Referring more in detail-to the drawing, the article shown by -way of illustration of the inventlon,` comprises a wall portion with inlays or the like effected in a novel way. The body is preferably made from a sheet of `fibre board or 25 the like. The portion shown comprises such a sheetv |10 upon a surface of which is a covering |1|. of the thermoplastic substance which after being subjected to heat and pressure, enters or penetrates into the interstices of the surface: portion of the sheet. Upon the covering |1| is a decorative layer or covering |12 which also may be of the thermoplastic substance with coloring matter, such as a dye, pigment or ller or the like, or may be a decorated sheet such as dcc'orat- 35 ed silk impregnated with the thermoplastic sub--` stance the latter being preferably transparent with or Without color or the like. On the covering I 12 is a decorative sheet-|13 which preferably is wood veneer which may or may not be covered 40 or coated with the thermoplastic 'substance as desired. The veneer sheet has die cut apertures |14, |15, |16 andv |11 in which the inlays are eventually located after heat and pressure have been applied to the assembly. Before the veneer 45 sheet is located in place, -inlay strips or ribbons or the like of any given or desired colors, texture, design, simulation, etc., such asstrips |18 and |19, -are so placed or located on the ycovering |12 as Vto be opposite or in registry with the apertures, such as the apertures |15l and |16, of the veneer sheet |13 when the latter is placed over the covering |12 as above explained. Such strips may also be placed to register with the aperturesv |14v and |11, but for the purpose of illustrating the inlaying with colored thermoplastic 'substance-,

the strips may be omitted under certain apere tures, such as apertures |14 and |11 whereby when the assembly' is later subjected to heat and pressure portions of the colored thermoplastic covering |12 will form the inlays in said apertures. Over the veneer is a covering |80 of trans'- parent thermoplastic substance. Figs.V 2 and 4 show in section the relationship of the elements before the assembly or aggregate is subjected to heat and pressure and Figs. 3 and 5 are similar views showing the same after the application of `pressi'ire and heat.

The thermoplastic substance may be applied either in liquid or sheet form, but preferably in the latter, wherein the sheet |1| is iirst placed upon the surface of the sheet |10; then sheet |12 is placed on sheet |1|, then strips |18 and |19 are located on sheet |12; then veneer |13 is placed over sheet |12 and supported upon strips |18 and |19, and then sheet 80 is placed on the veneer to extend over it and beyond it and over the sheet |12. The veneer sheet may be previously covered or coated with the thermoplastic substance, but if not, then a sheet of the thermoplastic substance will be applied to each face of the veneer. If the space between sheets |12 and |80 beyond the edges of the veneer should require it, strips, such as strips |8| and |82, may be used to avoid any shortage or insufficiency of the thermoplastic substance when fused and molded by the heat and pressure applied to the assembly.

'I'he assembly,or aggregate is then subjected to heat and pressure. This is effected by the application of properly shaped heated dies. The heat of and the pressure by the dies cause the Vthermoplastic substance to fuse and become fluidenter or penetrate into the interstices of the Upon applying pressure, the parts are compressed so that portions |83, |84, |85, |88, |81 and |88 of the fibrous sheet |10 will be displaced and will press into the spaces at each side of the veneer sheet and the apertures thereof as shown in Figs. 3 and'5. The thermoplastic substance of the layers |1|, |12, |8| and |82 likewise willbe displaced besides uniting and blending togetherl as also uniting Vand blending with the layer to form inlay portions |90, |9|, |92 and |93. See Fig. 5. In this way the united and blended displaced portions thereof illl the apertures |14,and |11 as also the spaces at the sides of the veneer sheet thus providing for molded-in inlays in said apertures, the inlays showing the color or decorative effect possessed by the layer or sheet |12 in said apertures and at the sides of the veneer sheets.

Similarly, the portions |18' and |19 of the strips |18 and |19 opposite the apertures |15 and |18 in the veneer sheet will be displaced and be located in and substantially ll the apertures |15 and |16, these portions |18' and |19' being otherwise embedded in the thermoplastic substance blending with the surface covering |80. See Figs. 3 and 5. Since the covering |80 is transparent, the color or decoration of the inlays |18' and |18 and the thermoplastic substance |12 or decorative sheet embedded therein, lif one be used, and the graining of veneer sheet |13, are all clearly visible. The effect produced is, in this' example, a veneer with colored or decorative inlays. The surface of the covering |80 being glossy or lustrous, gives the article a beautiful and elegant appearance.

After the compressing and molding are completed, the article and dies are cooled while maintaining the pressure, and then the dies are removed. On cooling the molded thermoplastic substance solidies so thatthe article is practically an integral unit.

Thus is provided a simple and novel method of inlaying by merely displacing the inlay material in the inlay apertures and so uniting the thermoplastic substance thereto as to maintain the inlays in place. The painstaking care previously required to accurately cut the inlay pieces to exact shape and size of the inlay recess, is, by the present invention, wholly avoided or eliminated.

If desired, when assembling the parts, each Y part may be coated with the thermoplastic substance and the coating allowed to dry, and then the parts assembled. The adherence and uniting of the parts will then be effected when the thermoplastic substance is fused or made fluidal under heat and pressure, or, instead of coating the parts as stated, and which is preferable, sheets of the thermoplastic substance may be placed upon the surfaces of the parts andthe aggregate then subjected to heat and pressure to fuse the thermoplastic sheets to unite the parts together in a unitary and rigid article.

When convenientl instead of deriving all of the heat from the dies to produce the desired effect, the assembly of the parts may be separately heated in any suitable manner, not sufficient to cause the thermoplastic substance to prematurely fuse or become plastic before the dies are applied. In such case, the dies will not need to be heated as much as when all of the heat necessary for the desired effect must be supplied wholly from the dies. The added heat when the dies are applied, will be suflicient to render the thermoplastic substance fluidal and become molded as described above. In that way a more thorough and a quicker thermoplastic action is effected, and the time of cooling is decreased. Less heat is necessary in the dies and hence the dies cool more quickly.

While I have disclosed an embodiment of the invention and a mode of producing it, it is to be understood that the invention is not limited thereto but comprehends other constructions,

.details arrangements ofv parts, features and process steps without departing from the spirit of the invention.

Having thus disclosed the invention, I claim:

1. A method of inlaying comprising juxtaposing an inlay element and a member having an inlay opening with a portion of said element in registry with the opening of'said member, embedding said element and member in a fused thermoplastic substance of a resinous base, and solidifying said substance to unite said element and member and to maintain the relation thereof.

2. A method of making an article with inlay comprising juxtaposing an inlay velement of nonplastic material, an inlay member having an inlay opening of an area substantially less than said element and overlying a part of said element, a sheet of brous material to form the aoeasas body oi the article and layers or coverings of a thermoplastic substance ot a reslnous base. subjecting the aggregate to heat and pressure to cause suchv a displacement of a portion oi' the inlay element as to enter and substantially illl `ment of sheet material extending into said opening to substantially illl it, and a covering oi a4 solidiiled thermoplastic vinyl resin oi the bond group CIrIzCHz'unlted to and uniting said element and member to form a substantially integral unit.

4. Aninlay structure comprising an inlay member having an inlay opening, an inlay element of sheet material extending over said opening and having a portion thereof so displaced as to substantially illl said opening, and a covering of a solidined thermoplastic vinylresin of the polymerization group united to and uniting said element and member to iorm a substantially integral unit. n

5. An article with an inlay structure comprising a body of ilbrous material, a covering oi solidiiled thermoplastic vinyl resin of the polymerization group united to said body and having embedded therein juxtaposed decorative elements oi' which one has aninlay opening and of which another has a portion so displaced as to form an inlay inl said opening.

' 6. An inlay structure comprising an inlay member having an inlay opening, an inlay element of sheet material oi such greater area than/said copening that regardless of the shape oi.' the opening'the element may be displaced to substantially fill the opening, said element having been so displaced, and a covering of a solidiiled v thermoplastic material united to and uniting said element and member to form a substantially integral unit.

7. An inlay structure comprising an inlay vmember having an inlay opening, an inlay element of sheet material so placed as to underlie said opening to give an inlay eiect, said element being of ,any shape but ofsuiilcient area to underlie the entire opening, and a covering of a solidied thermoplasticy material united to and uniting said element and member to form a substantially integral unit.

8. An inlay structure comprising an inlay member having an aperture, an inlay element juxtaposed with said member and being oi substantially greater area than said aperture so that a portion of said element registers with said aperture to appear therethrough. and bonding material to unite said member and element into a unitary structure.

EDWARD C. SLOAN. 

